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ENGINE ASSEMBLY REMOVAL

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Click here Click here
  1. Click here

    PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. Click here

    RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  3. Click here

    REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note:

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. Click here

    REMOVE RADIATOR SUPPORT OPENING COVER


    1. A01IS0M

      Remove the 3 clips.

    2. Detach the 4 hooks and remove the radiator support opening cover.

  5. Click here

    PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).

  6. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  7. Click here

    DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  8. Click here

    REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    (Click here)

  9. Click here

    REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. A01ISZQ

      Detach the wire harness clamp and disconnect the sensor connector.

    2. Remove the bolt and sensor.

    3. Disconnect the 2 vacuum hoses.

  10. Click here

    REMOVE OUTER COWL TOP PANEL


    1. A01IO5B

      Remove the 9 bolts and outer cowl top panel.

  11. Click here

    REMOVE FRONT BUMPER COVER

    (Click here)

  12. Click here

    REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01IOQE

      Remove the 2 clips.

    2. A01IPJ8

      Remove the 4 bolts.

    3. Detach the 2 hooks of the front lower bumper absorber from the installation holes in the body and remove the front lower bumper absorber.

  13. Click here

    REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IRQL

      Remove the 6 bolts and 10 clips.

    2. Remove the No. 1 engine under cover.

  14. Click here

    REMOVE NO. 2 ENGINE UNDER COVER


    1. A01IOL8

      Remove the 4 clips and No. 2 engine under cover.

  15. Click here

    REMOVE REAR ENGINE UNDER COVER RH


    1. A01IQ51

      Remove the 5 clips and rear engine under cover RH.

  16. Click here

    REMOVE REAR ENGINE UNDER COVER LH


    1. A01INGO

      Remove the 5 clips and rear engine under cover LH.

  17. Click here

    DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      Tip:

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01IUC4E01

      Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Table 1. Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -
  18. Click here

    DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Install a new gasket and the oil pan drain plug.

      38 N*m 387 kgf*cm 28 ft.*lbf
  19. Click here

    DRAIN MANUAL TRANSAXLE OIL


    1. A01IP1ME01

      Remove the filler plug and gasket.

      Table 2. Text in Illustration
      *1 Filler Plug
      *2 Drain Plug

    2. Remove the drain plug and gasket to drain the manual transaxle oil.

    3. Install a new gasket and the drain plug.

      39 N*m 400 kgf*cm 29 ft.*lbf
  20. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY

    (Click here)

  21. Click here

    REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01IP71

      Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp sub-assembly from the battery carrier, and then remove the battery clamp sub-assembly.

  22. Click here

    REMOVE BATTERY INSULATOR

  23. Click here

    REMOVE BATTERY

  24. Click here

    REMOVE BATTERY TRAY

  25. Click here

    REMOVE BATTERY CARRIER


    1. A01ISD1

      Detach the 2 clamps and disconnect the wire harness.

    2. Remove the 4 bolts and battery carrier.

  26. Click here

    REMOVE RADIATOR ASSEMBLY

    (Click here)

  27. Click here

    DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A01IQA7

      Remove the bolt and disconnect the discharge hose sub-assembly from the compressor assembly with pulley.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  28. Click here

    DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A01IPZC

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    2. Remove the O-ring from the suction hose sub-assembly.

      Note:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  29. Click here

    DISCONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01ISW7

      Slide the clamp and disconnect the No. 2 vacuum transmitting hose assembly from the intake manifold.

  30. Click here

    REMOVE NO. 3 AIR HOSE


    1. A01ISZ1

      Loosen the 2 hose clamps.

    2. Remove the No. 3 air hose from the No. 2 air tube and diesel throttle body assembly.

  31. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01IOT2

      Detach the clamp and disconnect the mass air flow meter connector.

    2. Slide the clamp and disconnect the PCV hose from the cylinder head cover sub-assembly.

    3. Slide the clamp and disconnect the air cleaner hose assembly from the turbocharger sub-assembly.

    4. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  32. Click here

    REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  33. Click here

    REMOVE AIR CLEANER CASE


    1. A01ITZL

      Remove the 3 bolts and air cleaner case.

  34. Click here

    REMOVE FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)


    1. A01IPL7

      Disconnect the 4 fuel hoses.

    2. A01IRKK

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  35. Click here

    REMOVE FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)


    1. A01IPJP

      Disconnect the 5 fuel hoses.

    2. A01IRKK

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  36. Click here

    REMOVE FUEL FILTER SUPPORT


    1. A01IQQY

      Raise the lever while pushing the lock on the lever, and disconnect the ECM connector.

      Note:

      After disconnecting the connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connector.

    2. A01IQC4

      Disconnect the connector.

    3. Detach the 2 clamps and disconnect the engine wire.

    4. A01INYZ

      Remove the bolt and disconnect the glow relay.

    5. Detach the 2 clamps and disconnect the wire harness.

    6. A01IPPR

      Remove the 3 bolts and fuel filter support.

  37. Click here

    REMOVE AIR CLEANER BRACKET


    1. A01ITN9

      Remove the 3 bolts and air cleaner bracket.

  38. Click here

    DISCONNECT HOSES AND CONNECTORS


    1. Remove the engine room No. 1 relay block cover.

    2. Disconnect the current sensor connector.

    3. A01ISG3

      Disconnect the 4 connectors.

    4. Remove the 2 nuts.

    5. Detach the 2 claws and disconnect the engine wire from the engine room No. 1 relay block.

    6. A01IUEL

      Remove the bolt and disconnect the ground cable.

    7. A01IOAN

      Detach the 4 clamps and disconnect the wire harness.

    8. Slide the clamp and disconnect the No. 1 fuel hose from the supply pump assembly.

    9. Slide the clamp and disconnect the No. 2 fuel hose from the No. 2 nozzle leakage pipe.

    10. A01IOEJ

      Slide the clamp and disconnect the vacuum pump hose from the vacuum pump assembly.

  39. Click here

    DISCONNECT INLET HEATER WATER HOSE


    1. A01IU86

      Slide the clamp and disconnect the inlet heater water hose from the cylinder head sub-assembly.

  40. Click here

    DISCONNECT OUTLET HEATER WATER HOSE


    1. Slide the clamp and disconnect the outlet heater water hose from the No. 3 water by-pass pipe.

  41. Click here

    REMOVE INTERCOOLER AIR HOSE


    1. A01IRFKE01

      Loosen the hose clamp and disconnect the intercooler air hose from the No. 1 air tube.

    2. Pull out the retainer and remove the intercooler air hose from the intercooler.

      Table 3. Text in Illustration
      *1 Retainer
  42. Click here

    DISCONNECT NO. 1 WATER BY-PASS HOSE


    1. A01IUQB

      Slide the clamp and disconnect the No. 1 water by-pass hose from the No. 4 water by-pass pipe.

  43. Click here

    DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01IQH9

      Remove the 2 pins and disconnect the 2 transmission control cable assemblies from the manual transaxle.

    2. Remove the 2 clips and disconnect the 2 transmission control cable assemblies from the transmission control cable bracket.

  44. Click here

    DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01IQWP

      Remove the 6 bolts and disconnect the clutch release cylinder assembly and clutch flexible hose bracket.

  45. Click here

    SECURE STEERING WHEEL


    1. A01ITFX

      Secure the steering wheel with the seat belt in order to prevent rotation.

      Tip:

      This operation is useful to prevent damage to the spiral cable.

  46. Click here

    REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A01IPW5

      Fold back the floor carpet, and then remove the 2 clips and then column hole cover silencer sheet.

  47. Click here

    DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01IQQD

      Remove the bolt.

      Note:

      Do not disconnect the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

    2. A01IPG7E01

      Put matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft.

      Table 4. Text in Illustration
      *1 Matchmark

    3. Disconnect the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

  48. Click here

    REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY


    1. A01IN1RE08

      Remove clip A and the No. 1 steering column hole cover and detach clip B from the body.

      Table 5. Text in Illustration
      *a Clip A
      *b Clip B
      *c Lip
      Note:

      Do not damage clip A or B.

  49. Click here

    REMOVE FRONT AXLE SHAFT NUT LH


    1. A01IP5HE01

      Using SST and a hammer, unstake the staked part of the front axle shaft nut.

      09930-00010
      Note:

      Loosen the staked part of the front axle shaft nut completely, otherwise the screw of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  50. Click here

    REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Perform the same procedure as for the LH side.

  51. Click here

    DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A01IOOVE03

      Remove the nut and disconnect the stabilizer link assembly from the front shock absorber with coil spring.

      Tip:

      If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.

  52. Click here

    DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  53. Click here

    REMOVE FRONT AXLE ASSEMBLY LH

    (Click here)

  54. Click here

    REMOVE FRONT AXLE ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  55. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01IRMNE01

      Using SST, remove the front drive shaft.

      09520-00031
      09520-01010
      Note:

      • Be careful not to damage the transaxle case oil seal, inboard joint boot or drive shaft dust cover.

      • Be careful not to drop the drive shaft.

  56. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY RH


    1. A01IR8P

      Remove the 2 bolts and pull out the drive shaft together with the drive shaft bearing case from the transaxle.

      Note:

      • Be careful not to damage the inboard joint boot or drive shaft dust cover.

      • Be careful not to drop the drive shaft.

  57. Click here

    REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. A01INJJ

      Remove the 2 bolts and front lower engine mounting bracket reinforcement.

  58. Click here

    REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01IS2K

      Remove the 4 bolts and front suspension member reinforcement LH.

  59. Click here

    REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01INC5

      Remove the 4 bolts and front suspension member reinforcement RH.

  60. Click here

    REMOVE FUEL HOSE PROTECTOR


    1. A01IQ9W

      Remove the fuel hose protector from the cylinder head sub-assembly.

  61. Click here

    INSTALL ENGINE HANGERS


    1. A01IPKAE01

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      40 N*m 408 kgf*cm 30 ft.*lbf
      Table 6. Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      Tip:
      Table 7. Part No.
      No. 1 engine hanger 12281-26040
      No. 2 engine hanger 12282-26010
      Bolt 90105-W0042

      • Insert the claw of the No. 1 engine hanger into the hole of the cylinder head sub-assembly.

      • Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head sub-assembly.

  62. Click here

    REMOVE ENGINE WITH TRANSAXLE


    1. A01ISCQ

      Remove the bolt and disconnect the cable bracket.

    2. A01IT3W

      for DPF:

      Detach the 3 clamps and disconnect the wire harness.

    3. Set an engine lifter underneath the engine.

      Tip:

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. A01IR8D

      Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH.

    5. A01IQUU

      Remove the bolt and nut, and disconnect the engine mounting insulator LH.

    6. A01ISQ8

      Remove the 6 bolts and front suspension member rear brace RH and front suspension member rear brace LH.

    7. Remove the 2 bolts and front suspension crossmember sub-assembly.

    8. A01IT7H

      Remove the 6 bolts and front crossmember sub-assembly.

    9. Carefully remove the engine with transaxle from the vehicle.

    10. Attach an engine sling device and hang the engine with a chain block.

  63. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01IOT4E01

      Remove the through bolt, nut and front engine mounting insulator.

      Table 8. Text in Illustration
      *1 Through Bolt
      *2 Nut
  64. Click here

    REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A01IQL4

      Remove the 3 bolts, 2 nuts and rear engine mounting insulator.

  65. Click here

    REMOVE NO. 1 AIR TUBE


    1. A01IS5M

      Loosen the hose clamp.

    2. Remove the 2 bolts and No. 1 air tube.

  66. Click here

    REMOVE STARTER ASSEMBLY


    1. A01INZ3

      Disconnect the starter connector.

    2. Open the terminal cap, remove the nut and disconnect the starter wire.

    3. A01INO6

      Remove the 2 bolts and starter assembly.

  67. Click here

    REMOVE ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine, and then remove the bracket bolts and engine wire from the engine.

  68. Click here

    REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01IS6T

      Remove the 3 bolts and front engine mounting bracket.

  69. Click here

    REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01IRVA

      Remove the 5 bolts and rear engine mounting bracket.

  70. Click here

    REMOVE ENGINE MOUNTING BRACKET LH

    Tip:

    Perform this procedure only when replacement of the engine mounting bracket LH is necessary.


    1. A01INOT

      Remove the 4 bolts and engine mounting bracket LH.

  71. Click here

    REMOVE ENGINE MOUNTING INSULATOR LH

    Tip:

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.


    1. A01ISA9

      Remove the 4 bolts and engine mounting insulator LH.

  72. Click here

    REMOVE ENGINE MOUNTING INSULATOR RH

    Tip:

    Perform this procedure only when replacement of the engine mounting insulator RH is necessary.


    1. A01IRH7

      Remove the 3 bolts and engine mounting insulator RH.

  73. Click here

    REMOVE OIL PAN INSULATOR


    1. A01IS9M

      Remove the 2 bolts and oil pan insulator.

  74. Click here

    REMOVE STIFFENER PLATE RH


    1. A01IQ9A

      Remove the 4 bolts and stiffener plate RH.

  75. Click here

    REMOVE STIFFENER PLATE LH


    1. A01IN9C

      Remove the 4 bolts and stiffener plate LH.

  76. Click here

    REMOVE MANUAL TRANSAXLE ASSEMBLY

    (Click here)

  77. Click here

    REMOVE CLUTCH COVER ASSEMBLY


    1. A01IRLCE01

      Place matchmarks on the clutch cover and flywheel.

      Table 9. Text in Illustration
      *1 Matchmark

    2. Loosen each set bolt 180° at a time until the spring tension is released.

      Note:

      Be sure to uniformly loosen the bolts 180° at a time according to the order in the illustration.

    3. Remove the set bolts and pull off the clutch cover to remove it.

      Note:

      Do not drop the clutch disc.

  78. Click here

    REMOVE CLUTCH DISC ASSEMBLY

    Note:

    Keep the lining part of the clutch disc, the pressure plate, and the surface of the flywheel away from oil and foreign matter.

  79. Click here

    REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01IPB5E01

      Using SST, hold the crankshaft pulley.

      09213-58014 91551-80840
      09330-00021
    2. A01IP7G

      Using a T55 "TORX" socket wrench, remove the 8 bolts and flywheel sub-assembly.

  80. Click here

    INSTALL ENGINE TO ENGINE STAND


    1. Install the engine to an engine stand, and remove the sling device and chain block from the engine.

    2. Remove the 2 bolts and No. 1 engine hanger and No. 2 engine hanger.